KR101316435B1 - Insert film for interior material of car with exelent image clarity and chemical resistance and method for manufacturing the same - Google Patents

Abstract

The present invention relates to an insert film for automotive interior materials and a method of manufacturing the same, the first transparent resin layer having a thermosetting layer for forming a surface layer, and a second transparent resin layer for compensating high gloss and scratch resistance and providing an appearance effect. The present invention relates to a method for manufacturing a molding insert film having a printing layer and a substrate layer.

Description

INSERT FILM FOR INTERIOR MATERIAL OF CAR WITH EXELENT IMAGE CLARITY AND CHEMICAL RESISTANCE AND METHOD FOR MANUFACTURING THE SAME}

The present invention relates to an insert film for automobile interior materials and a method for manufacturing the same, and a composition for maintaining the glossiness of a film before molding in a high temperature molding process and maintaining surface properties such as chemical resistance, and a laminated structure made of the composition. It relates to the technology to provide.

Insert decoration sheet is used in the case of automotive interior materials, home appliances, etc. The prior art has realized a variety of patterns and metal texture through gravure printing.

However, as differentiated designs such as indirect lighting effects on LED lighting have been developed, the demand for improving the characteristics of the insert film for automobile interior materials has been continuously increasing.

In particular, it is required to improve the characteristics of transparency or sensibility for transmitting or reflecting LED lighting, and surface characteristics such as chemical resistance should be improved to realize various patterns.

However, the current insert film has a problem such that gloss loss occurs during the high temperature molding process, so that glossiness cannot be maintained before molding and surface properties are degraded.

The present invention forms an insert film having a surface structure in which a thermosetting first transparent resin layer made of a hard coating layer and a second transparent resin layer for maintaining gloss are combined to maintain the gloss of the film before molding even at a high temperature thermoforming process. It is an object of the present invention to provide an insert film for automobile interior which can be made while maintaining high sensibility and does not exhibit O / Peel phenomenon.

In addition, the present invention forms a decorative layer (printing layer) on the base material layer, and by sequentially laminating the above-mentioned second transparent resin layer and the first transparent resin layer on the top, while showing a more vivid decorative pattern, It is an object of the present invention to provide a method for easily manufacturing an insert film for automobile interior having chemical resistance, abrasion resistance, scratch resistance, light resistance and weather resistance.

Insert film for automobile interior according to an embodiment of the present invention includes a surface treatment layer, a printed pattern layer and a substrate layer from above, the surface treatment layer is a thermosetting first transparent resin layer and a thermoplastic second transparent water from above It is characterized by consisting of a laminated structure of the ground layer.

Here, the first transparent resin layer includes at least one of an acrylic resin and a urethane resin as a base resin, the base resin is preferably made of 70 to 100% by weight acrylic resin and 0 to 30% by weight urethane resin. .

Next, the first transparent resin layer is based on 100 parts by weight of the base resin, 4 to 8 parts by weight of isocyanate curing agent, 20 to 40 parts by weight of methyl ethyl ketone, 20 to 40 parts by weight of toluene, and 150 to methyl isobutyl ketone. It is formed of a resin composition containing 200 parts by weight and 50 to 70 parts by weight of ethyl acetate, but preferably formed with a thickness of 1 to 15㎛.

Next, the second transparent resin layer is formed of at least one of an acrylic resin, a modified acrylic resin, an olefin resin, a urethane resin, and a PET-G resin, but preferably at a thickness of 50 to 150 μm.

Next, the base layer preferably uses at least one of ABS resin, polycarbonate (PC) resin, vinyl chloride (PVC) resin, thermoplastic polyurethane (TPU) resin, and olefin resin.

In addition, the insert film manufacturing method for automobile interior according to an embodiment of the present invention (a) providing a first release film, the first release film comprising at least one of an acrylic resin and a urethane-based resin as a base resin Forming a transparent resin layer, (b) preparing a second release film, forming a printing layer on the second release film, and (c) transferring the printing layer on the substrate layer, and Removing the second release film; and (d) laminating a second transparent resin layer made of at least one of an acrylic resin, a modified acrylic resin, an olefin resin, a urethane resin, and a PET-G resin on top of the printing layer. And (e) transferring the first transparent resin layer on the second transparent resin layer.

Here, at least one of the first release film and the second release film uses a PET film, the surface roughness (Roughness) is used in the 00 ~ 000 (RMS), or the specular reflectance (Dullness) using less than 0.1 It is preferable.

The insert film for automobile interior according to the present invention forms a surface layer of a two-layer structure in which a first transparent resin layer for improving surface properties and a second transparent resin layer for maintaining glossiness are formed, and thus a high linearity in high temperature thermoforming process is achieved. It maintains spirituality and prevents orange peel from appearing, thus improving product quality.

In addition, the present invention can be produced in various forms while further improving the properties of the insert film by utilizing the substrate layer, the decorative layer (printing layer) and the PET release layer appropriately, high sensibility, chemical resistance, wear resistance, scratch resistance The present invention provides an effect of easily manufacturing the insert film for automobile interior having the resistance to light, weather resistance and the like.

1 is a flowchart of manufacturing an insert film for automobile interior according to an embodiment of the present invention.
2 is a cross-sectional view showing an insert film structure for automobile interior according to an embodiment of the present invention.
3 is a graph showing the optical characteristics of the release film according to the present invention.

Hereinafter, the insert film for automobile interior according to an embodiment of the present invention will be described in detail.

BRIEF DESCRIPTION OF THE DRAWINGS The advantages and features of the present invention, and the manner of achieving them, will be apparent from and elucidated with reference to the embodiments described hereinafter in conjunction with the accompanying drawings. It should be understood, however, that the invention is not limited to the disclosed embodiments, but is capable of many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, To fully disclose the scope of the invention to those skilled in the art, and the invention is only defined by the scope of the claims. Like reference numerals refer to like elements throughout the specification.

1 is a flowchart of manufacturing an insert film for automobile interior according to an embodiment of the present invention.

Referring to FIG. 1, first, as a first process, a step of preparing a first release film (S100) and a first transparent resin layer including at least one of an acrylic resin and a urethane resin as a base resin on the first release film are provided. Forming step (S110) is performed.

Next, as a second process, a step (S120) of preparing a second release film is performed, a step (S130) of forming a printing layer on the second release film is performed, and the print layer is transferred onto the base layer. Performing step (S140), removing the second release film (S150) and the second transparent made of at least one of an acrylic resin, a modified acrylic resin, an olefin resin, a urethane resin and a PET-G resin on the printed layer A step (S160) of laminating the resin layer is performed.

Thereafter, transferring the first transparent resin layer of the film laminated structure formed in the first process to the upper portion of the second transparent resin layer of the film laminated structure formed in the second process (S170).

Then, finally, the step of removing the first release film (S180) is performed to complete the insert film production according to the present invention.

In the conventional case, an insert film made of a base layer, a print layer, and a transparent resin layer was manufactured from below as formed in the second process.

However, in this case, there is a high risk that the transparent resin layer is damaged in the high temperature thermoforming process, and in particular, there is a problem in that the glossiness is significantly lowered.

Therefore, in the present invention, further to form a first transparent resin layer for protecting the second transparent resin layer to maintain the gloss and clarity, in order to prevent the second transparent resin layer is also damaged during the high temperature process, a separate In the first process, a first transparent resin layer is formed, and the first transparent resin layer is transferred to the second transparent resin layer and coated.

By the production method according to the present invention, it is possible to manufacture an insert transfer film excellent in chemical resistance, wear resistance, scratch resistance, light resistance and weather resistance, while maintaining the original fidelity and glossiness of the transfer film.

In addition, when forming the insert film structure divided into the first step and the second step as described above, depending on the surface characteristics of the release film used in each step, it is possible to obtain a variety of surface treatment effects, such as gloss effect, matte effect and mirror surface effect Can be.

In the following, the insert film structure for automobile interior materials of the present invention manufactured by the above-described manufacturing method will be described, and the composition constituting each layer and its specific characteristics will be described.

2 is a cross-sectional view showing an insert film structure for automobile interior according to an embodiment of the present invention.

Referring to FIG. 2, a second transparent resin layer having a structure of a base layer 200, a printing layer 210, and a surface treatment layer 240 from the bottom, wherein the surface treatment layer 240 has gloss and stiffness ( 220 and the first transparent resin layer 230 having surface characteristics such as chemical resistance.

Here, the first transparent resin layer of the surface treatment layer according to the present invention can be configured by coating a thermosetting resin.

The first transparent resin layer performs a sun block function and protects the product from environmental factors such as chemical resistance, abrasion resistance, scratch resistance, light resistance, and weather resistance.

Such physical properties can be achieved by curing the acrylic resin composition. However, the surface coating layer through such curing may limit the molding processability of the sheet in the molding process by factors such as curing density and coating thickness.

Therefore, the first transparent coating layer 230 according to the present invention At least one of an acrylic resin and a urethane resin is included as a base resin, and the base resin is preferably made of an acrylic resin of 70 to 100% by weight and a urethane resin of 0 to 30% by weight.

More specifically, based on 100 parts by weight of the base resin, 4 to 8 parts by weight of isocyanate curing agent, 20 to 40 parts by weight of methyl ethyl ketone, 20 to 40 parts by weight of toluene, 150 to 200 parts by weight of methyl isobutyl ketone and ethyl acetate Furnace is formed of a resin composition containing 50 to 70 parts by weight, it is preferable to adjust the composition in consideration of the curing density and the above-described surface properties.

At this time, the thickness of the first transparent coating layer 230 is preferably formed about 5 ~ 15㎛. When the thickness of the first transparent coating layer 230 is formed to less than 5㎛ it may be difficult to secure the surface properties, when formed with a thickness of more than 15㎛, it may be difficult to transfer to the second transparent coating layer 220. Defects such as orange peel (O / peel) may occur.

Next, the second transparent resin layer 220 is a thermoplastic film structure, and acts as a layer that affects the gloss retention and the clarity of the transfer film.

Conventionally, the surface shape has changed due to the deterioration of the substrate layer composed of thermoplastic resin and the printing layer composed of thermoplastic resin during high temperature molding process. In particular, the base layer, which is a thermoplastic resin, has a large surface shape change before and after molding through a TEM analysis.

The hole (Hole) is generated on the surface of the substrate layer mainly due to the change in the shape of the rubber particles in the substrate layer, thereby increasing the roughness (Roughness) significantly.

In addition, the roughness also affects the surface shape change of the transparent resin layer, resulting in a decrease in the surface gloss of the product.

In order to prevent such a shape, a method of increasing the thickness of the thermosetting surface coating layer may also be examined. However, this may cause a deterioration in molding processability due to the high thickness of the thermosetting, and there is a problem in application.

Therefore, in the present invention, the laminated structure of the first and second transparent resin layers was introduced in order to maintain an appropriate surface treatment layer thickness, and through this, it was possible to limit the influence of the surface shape change of the base layer on the surface of the product.

As used herein, the second transparent resin layer 220 of the present invention may be configured as a thermoplastic resin in consideration of molding processability, and may include at least one of an acrylic resin, a modified acrylic resin, an olefin resin, a urethane resin, and a PET-G resin. Form.

At this time, the combination of the composition is controlled through a test, such as scratch resistance, it is preferable to ensure the appropriate hardness to complement the first transparent resin layer 230.

In addition, in consideration of the change in the surface shape of the base layer 200, the thickness of the second transparent resin layer 220 is preferably formed to be 50 to 150 μm. When the thickness of the second transparent resin layer 220 is less than 50 μm, desired surface properties may not be obtained.

In addition, when the thickness of the second transparent resin layer 220 is increased, it is advantageous to realize the gloss effect of the product, but since the thickness and the price of the entire product may be unnecessarily increased, the maximum thickness is preferably limited to 150 μm or less. Do.

Next, as a layer that is largely involved in the mechanical properties of the insert molding film of the base layer 200 according to the present invention, it should have excellent moldability. Therefore, the base layer 200 according to the present invention can be selected to fit the molding process, for example, in the case of film insert injection molding, ABS sheet is suitable.

In addition, in the present invention, the base layer 200 may be formed of at least one of ABS, PC, PVC, PC / ABS, TPU, and an olefin resin.

Next, the print layer 210 according to the present invention is a layer configured to make the decorative effect of the base layer 200 more prominent, and serves to provide a more realistic decorative effect or to secure an aesthetic effect. .

Next, since the insert transfer film according to the present invention uses the first and second release films as described above, various surface effects such as gloss, matte and specular effects can be realized when appropriately used.

At this time, as the first and second release films, it is possible to use a high-gloss PET film to implement the gloss.

In the case of a general PET film, there is a processing mark (Tack) due to the nature of the material, which is a major cause for blocking (blocking) occurs. In order to prevent this, for general purpose PET film, the surface roughness is intentionally configured. When such a PET film is used, the roughness may be transferred to the surface and thus may be utilized in the present invention.

In addition, the roughness of the PET film is enough to implement the sensibility and specular effect enough, it is unnecessary to use excessively.

Therefore, the roughness of the PET film according to the present invention preferably uses a PET film whose specular reflectance value (Du value), which is a conversion value of roughness, is 1.0 or less (when DOI meter is measured) under optical conditions.

Here, the roughness of the PET surface is a physical feature, roughness is the main cause affects the optical properties. And the value that can quantify this optical characteristic is Du value.

3 is a graph showing the optical characteristics of the release film according to the present invention.

In FIG. 3, the line denoted by H-1 (Du value 17.6) is used as a normal PET, and the line denoted as B-1 (Du value 3.2) is a surface treatment of the general PET to reduce roughness, and B- The line labeled 2 (Du value 1.0) uses PET of optical grade (Grade).

As described above, in the case of the PET release film used for the transfer, it can be confirmed that the Du value of the product surface has a large correlation according to the roughness.

Hereinafter, the surface properties and the screening properties according to the present invention will be described with reference to specific examples and comparative examples according to the present invention.

Comparative Example 1

Using a PET film as a first release film, the first transparent resin layer is coated on the first release film, the first transparent resin layer 100 parts by weight of the base resin consisting of 70% by weight acrylic resin and 30% by weight urethane resin A mixed resin composition comprising 6 parts by weight of isocyanate-based curing agent, 30 parts by weight of methyl ethyl ketone, 30 parts by weight of toluene, 180 parts by weight of methyl isobutyl ketone, and 60 parts by weight of a mixed solvent composed of ethyl acetate was used.

At this time, the thickness of the first transparent resin layer was formed to 10㎛, the second transparent resin layer was applied to the acrylic film of 50㎛.

Comparative Example 2

Using a PET film as a first release film, the first transparent resin layer is coated on the first release film, the first transparent resin layer 100 parts by weight of the base resin consisting of 85% by weight acrylic resin and 15% by weight urethane resin A mixed resin composition comprising 6 parts by weight of isocyanate curing agent, 30 parts by weight of methyl ethyl ketone, 30 parts by weight of toluene, 180 parts by weight of methyl isobutyl ketone, and 60 parts by weight of a mixed solvent consisting of ethyl acetate was coated.

At this time, the thickness of the first transparent resin layer was formed to 10㎛, the second transparent resin layer was applied to the acrylic film of 50㎛.

Comparative Example 3

Using a PET film as a first release film and coating a first transparent resin layer on the first release film, the first transparent resin layer is an isocyanate-based curing agent based on 100 parts by weight of the base resin made of 100% by weight of an acrylic resin. A mixed resin composition consisting of 6 parts by weight, 30 parts by weight of methyl ethyl ketone, 30 parts by weight of toluene, 180 parts by weight of methyl isobutyl ketone and 60 parts by weight of a mixed solvent consisting of ethyl acetate was coated.

At this time, the thickness of the first transparent resin layer was formed to 10㎛, the second transparent resin layer was applied to the acrylic film of 50㎛.

Comparative Example 4

Using a PET film as a first release film and coating a first transparent resin layer on the first release film, the first transparent resin layer is an isocyanate-based curing agent based on 100 parts by weight of the base resin made of 100% by weight of an acrylic resin. A mixed resin composition consisting of 4 parts by weight, 30 parts by weight of methyl ethyl ketone, 30 parts by weight of toluene, 180 parts by weight of methyl isobutyl ketone and 60 parts by weight of a mixed solvent composed of ethyl acetate was coated.

At this time, the thickness of the first transparent resin layer was formed to 10㎛, the second transparent resin layer was applied to the acrylic film of 50㎛.

Example 1

A PET film having a surface roughness Du 1.0 is used as a first release film, and the first transparent resin layer is coated on the first release film, and the first transparent resin layer is 100 parts by weight of a base resin made of 100% by weight of an acrylic resin. A mixed resin composition comprising 4 parts by weight of isocyanate-based curing agent, 30 parts by weight of methyl ethyl ketone, 30 parts by weight of toluene, 180 parts by weight of methyl isobutyl ketone and 60 parts by weight of a mixed solvent consisting of ethyl acetate was coated.

At this time, the thickness of the first transparent resin layer was formed to 15㎛, the second transparent resin layer was applied to the acrylic film of 50㎛.

Example 2

The optical PET film having a Du of 1,0 or less is used as the first release film, and the first transparent resin layer is coated on the first release film, but the first transparent resin layer is made of 100% by weight of an acrylic resin. A mixed resin composition comprising 4 parts by weight of isocyanate-based curing agent, 30 parts by weight of methyl ethyl ketone, 30 parts by weight of toluene, 180 parts by weight of methyl isobutyl ketone and 60 parts by weight of a mixed solvent consisting of ethyl acetate was coated.

At this time, the thickness of the first transparent resin layer was formed to 5㎛, the second transparent resin layer was applied to the acrylic film of 50㎛.

Example 3

Du uses an optical PET film of 1,0 or less as a first release film and coats the first transparent resin layer on the first release film, wherein the first transparent resin layer is made of 100% by weight of an acrylic resin. A mixed resin composition composed of a resin composed of 4 parts by weight of an isocyanate curing agent, 30 parts by weight of methyl ethyl ketone, 30 parts by weight of toluene, 180 parts by weight of methyl isobutyl ketone, and 60 parts by weight of a mixed solvent composed of ethyl acetate was used. Coated.

At this time, the thickness of the first transparent resin layer was formed to 10㎛, the second transparent resin layer was applied to the acrylic film of 50㎛.

Comparative Example 5

Formed in the same manner as in Example 4, using the PET film having a surface roughness of 2.0 to form a first transparent resin layer.

Comparative Example 6

Formed in the same manner as in Example 5, using a PET film Du of 1.5 to form a first transparent resin layer.

Next, samples of the examples and the comparative examples were taken, and the properties of chemical resistance, surface hardness and screening were examined.

[Chemical resistance]

After laminating the specimens according to practical examples and comparative examples on a white cloth and an acrylic plate, applying 0.25g of the sunscreen on the front, pressing the acrylic plate tightly and leaving the 80 ± 2 ° C constant temperature chamber and removing the white cloth and the acrylic plate. Powders were measured using a chemical test method called Sun-Block, which was performed after washing with a room temperature / neutral detergent, drying, visual inspection, adhesion (3 times), and scratch resistance (0.8 kgf, 1 time). The results are shown in Table 1 below.

[Surface hardness]

The surface of specimens prepared in accordance with JIS K 6718 or under the conditions equivalent thereto shall be loaded with a load (N {kgf}) of 4.9 {0.5}, a stroke of 100 ± 5 and a frictional speed of 100 mm / sec. It was made into conditions.

As for the scratcher, a tip diameter of 3 mm and a tip angle of 0.5 R sapphire were used.

In addition, the measurement results are classified into the following grades and shown in Table 1 below.

Grade 5 showed a scratch width of less than 20 ㎛ due to almost no surface damage (Excellent, Hardly any scratch). Class 4 shows a case where the scratch width is 100 ~ 200㎛ with no apparent scratch. Grade 3 shows a case where the scratch width is 200 ~ 300㎛ with a fine surface damage (Fine scratch). Grade 2 showed a scratch width of 300 ~ 400㎛ with clear scratch whitening. Class 1 was a badly gouged scratch path with a scratch width of 400 μm.

As can be seen with reference to Table 1 below, the film according to the present invention exhibited a similar or higher grade of hardness than the conventional case.

[Sunyoungseong]

Use the BKY Wave Scan (measurement equipment name) to measure the selectivity of the product surface. The measuring method obtains a value corresponding to the surface roughness RMS as a value for the Du value in an optical profile obtained after scanning a 10 cm length.

In this case, the optical meaning of Du is defined as the amount of scattered light with respect to the amount of incident light.

Next, summarized the experimental results are shown in Table 1 below.

[Table 1]

As described above, the insert film for automobile interiors according to the present invention forms a surface layer of a two-layer structure in which a first transparent resin layer for improving surface properties and a second transparent resin layer for maintaining gloss are formed, thereby providing high temperature heat. In the molding process, high stiffness can be maintained and the product quality can be improved by preventing the appearance of orange peel.

In addition, the present invention can be produced in various forms while further improving the properties of the insert film by utilizing the substrate layer, the decorative layer (printing layer) and the PET release layer appropriately, high sensibility, chemical resistance, wear resistance, scratch resistance The insert film for automobile interior having the resistance, light resistance and weather resistance can be easily produced.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the invention is not limited to the disclosed exemplary embodiments, but, on the contrary, Modification is possible. Accordingly, the spirit of the present invention should be understood only in accordance with the following claims, and all equivalents or equivalent variations thereof are included in the scope of the present invention.

S100: preparing the first release film
S110: forming the first transparent resin layer
S120: preparing the second release film
S130: printing layer forming step
S140: transferring the base layer
S150: removing the second release film
S160: second transparent resin layer lamination step
S170: transferring the first transparent resin layer to the second transparent resin layer
200: substrate layer 210: printed layer
220: second transparent resin layer 230: first transparent resin layer
240: surface treatment layer

Claims (11)

Including a surface treatment layer, a printed pattern layer, and a substrate layer from above,
The surface treatment layer is made of a laminated structure of a thermosetting first transparent resin layer and a thermoplastic second transparent resin layer from above,
The first transparent resin layer
At least one of an acrylic resin and a urethane resin is included as a base resin,
The first transparent resin layer
4 to 8 parts by weight of isocyanate curing agent, 20 to 40 parts by weight of methyl ethyl ketone, 20 to 40 parts by weight of toluene, 150 to 200 parts by weight of methyl isobutyl ketone and 50 to 70 parts by weight of ethyl acetate, based on 100 parts by weight of the base resin. Insert film for automobile interior, characterized in that consisting of a resin composition comprising a weight part.
delete The method of claim 1,
The base resin
Insert film for automobile interior, characterized in that consisting of 70 to 100% by weight acrylic resin and 0 to 30% by weight urethane resin.
delete The method of claim 1,
The first transparent resin layer
Insert film for automobile interior, characterized in that having a thickness of 1 ~ 15㎛.
The method of claim 1,
The second transparent resin layer
An insert film for automobile interiors, comprising at least one of an acrylic resin, a modified acrylic resin, an olefin resin, a urethane resin, and a PET-G resin.
The method of claim 1,
The second transparent resin layer
Insert film for automotive interior, characterized in that having a thickness of 50 ~ 150㎛.
The method of claim 1,
The base layer is
An insert film for automobile interiors comprising at least one of ABS resin, polycarbonate (PC) resin, vinyl chloride (PVC) resin, thermoplastic polyurethane (TPU) resin, and olefin resin.
(a) providing a first release film and forming a first transparent resin layer including at least one of an acrylic resin and a urethane resin as a base resin on the first release film;
(b) preparing a second release film and forming a printed layer on the second release film;
(c) transferring the printed layer onto the base layer, and removing the second release film;
(d) laminating a second transparent resin layer made of at least one of an acrylic resin, a modified acrylic resin, an olefin resin, a urethane resin, and a PET-G resin on the printed layer; And
(e) transferring the first transparent resin layer on the second transparent resin layer;
The first transparent resin layer
At least one of an acrylic resin and a urethane resin is included as a base resin,
The first transparent resin layer
4 to 8 parts by weight of isocyanate curing agent, 20 to 40 parts by weight of methyl ethyl ketone, 20 to 40 parts by weight of toluene, 150 to 200 parts by weight of methyl isobutyl ketone and 50 to 70 parts by weight of ethyl acetate, based on 100 parts by weight of the base resin. Method for manufacturing an insert film for automobile interiors, characterized in that formed to be made of a resin composition comprising a weight part.
10. The method of claim 9,
At least one of the first release film and the second release film
Method for producing an insert film for automobile interior, characterized in that the use of PET film.
The method of claim 10,
The PET film
A method for producing an insert film for automobile interiors, characterized in that the reflectance (Dullness value) is 1.0 or less.

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